Here we go!! 1991 110 torn down - Defender Source
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  #1  
Old January 21st, 2018, 06:46 PM
Stealthsr71
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Jeff Innes
1991 Defender 110
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Location: Ponce Inlet, Florida
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Here we go!! 1991 110 torn down

I am a new Defender owner (1 year, 20 miles) but I have always had a fascination for defenders. In Dec 16' I purchased what appeared to be a pretty good 110. On my 3rd time driving it, the fork was punched through in the clutch. Being a novice to these trucks, I took on the repairs myself after reading and knowing I am good with my hands.

First I thought it was the M/C or Slave and replaced all hydraulics prior to digging in. After reading and posting on here, my suspicion was correct that the fork was punched. Some told me to pull an engine, another told me to roll down the windows and take the floor out which I did. Replaced all clutch parts, but in doing so one thing led to another and now I have the truck all torn down. (the clutch works perfect now)

Couple pics of the clutch change. Next few are of the truck torn down.

Now i know some will say I should have put the truck back together and drive the crap out of it, but you must know this is a hobby for me. A slow one, as my wife and I adopted our son unexpectedly the exact same day my truck was delivered to my door. Wasn't even home to test drive. lol. next son is due in next 10 days.

So here we are with a slow project, but should be a fun one.

For you professionals with this, what should I be replacing, fixing, anything you can think of from knowledge I am open to your ideas.
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  #2  
Old January 21st, 2018, 06:59 PM
cowboy
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steven
'84 110 & '90 127 LHD 2-carb V8's
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What motor is in it?
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  #3  
Old January 21st, 2018, 07:06 PM
Stealthsr71
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Jeff Innes
1991 Defender 110
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200TDI with LT77
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  #4  
Old January 21st, 2018, 07:43 PM
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Russell
1985 LR Ninety 200tdi
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Bushings good? Frame good? If so put it back together and drive it. If you just want to throw some $ at it you could upgrade to a r380, or paint it or something.
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  #5  
Old January 21st, 2018, 07:58 PM
cowboy
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steven
'84 110 & '90 127 LHD 2-carb V8's
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Put the new Cummins in it?
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  #6  
Old January 21st, 2018, 08:56 PM
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KGH
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#1-'13 110SW,#2-'87 127,#3-'12 LR4
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Yank the body, galvy the chassis, ensure bulkhead good, paint, reassemble and drive.

There will always be stuff to fix and putter around with.
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  #7  
Old January 21st, 2018, 09:15 PM
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Eric Wages
1988 D110 300tdi/R380
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Yeah man! Welcome to my world. Only now, nearly 3 years later, am I actually driving my truck around. It's got ~250 miles on it, that's it! Full build thread on here.

I searched for places to get my chassis galvy dipped in the southeast and didn't find anyone that would take one. I ended up ordering a new Richards Chassis from the UK when the GBP was at an all-time low.

Good luck and don't let the #landroverbdsm wear you down too much!
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  #8  
Old January 22nd, 2018, 09:42 AM
Stealthsr71
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Jeff Innes
1991 Defender 110
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Thanks Eric, I spoke with you about the new doors from SP4x4. They should be inbound in the next few days.

Goal at the moment, is to start with an on the chassis build. I am going to have the rest of the truck blasted, and painted properly, rebuild dash, all new wiring, interior etc.

The chassis and bulkhead are solid and there is little to no rust. What is there is just surface and can be brushed off and coated with por15.

I hope in some years down the road when my boys are a few years old that we can do a Chassis change over and upgrade the motor.

Since the truck is wide open, I was wondering if anything else should get replaced? Brake lines, Fuel Tank, Fuel Pump, etc.
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  #9  
Old January 22nd, 2018, 09:46 AM
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TheOneTen
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Eric Wages
1988 D110 300tdi/R380
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Quote:
Originally Posted by Stealthsr71 View Post
Thanks Eric, I spoke with you about the new doors from SP4x4. They should be inbound in the next few days.

Goal at the moment, is to start with an on the chassis build. I am going to have the rest of the truck blasted, and painted properly, rebuild dash, all new wiring, interior etc.

The chassis and bulkhead are solid and there is little to no rust. What is there is just surface and can be brushed off and coated with por15.

I hope in some years down the road when my boys are a few years old that we can do a Chassis change over and upgrade the motor.

Since the truck is wide open, I was wondering if anything else should get replaced? Brake lines, Fuel Tank, Fuel Pump, etc.
Getting as much of the INTERIOR of the chassis as possible is something you should attempt to do. These things rust from the inside out.

Brake lines? Yes.

Fuel pump? If an old diesel defender, there's no pump in the tank in the classical sense. It's a lift pump on the side of the engine that pressurizes the lines/fuel filter, then into the high pressure pump. Change? Sure. Why not. It's easy while exposed and a pain if not.

I changed to diesel-friendly rubber lines instead of the nylon mess.

Fuel tank? Inspect and replace as necessary. They are *cheap* if you need to replace it later
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  #10  
Old January 22nd, 2018, 10:39 AM
scrubs
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henery
1974
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Didn't mention what the long term results are but I'd be going into the "sound proofing world" if it were mine and where your at. Nothing worse than being overlooked when a person had the opportunity after the fifth time hearing "what?" taking a family or a friend out for a ride.
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  #11  
Old January 22nd, 2018, 11:05 AM
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Eric Wages
1988 D110 300tdi/R380
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Quote:
Originally Posted by scrubs View Post
Didn't mention what the long term results are but I'd be going into the "sound proofing world" if it were mine and where your at. Nothing worse than being overlooked when a person had the opportunity after the fifth time hearing "what?" taking a family or a friend out for a ride.
It's a rabbit hole of research. I consider my cabin "acceptable" at this point, but will be adding additional material to the doors, for both sound reduction as well as thermal barrier.

Adding the seats into the back would make a good difference too.

I'm likely going to throw a horse stall mat on top of the carpet in the rear to keep stuff from slipping all over the place.

Also need to add a subwoofer to make the music drown out the noise
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  #12  
Old January 22nd, 2018, 12:10 PM
DiscoDavis
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C Davis
1990 110, 1995 Disco
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Looks nice but get it done ASAP. Too many long term thread of torn down cars where they haven't been touched in months/years.

Drive it and fix it when it breaks.
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  #13  
Old January 22nd, 2018, 12:42 PM
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KGH
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Quote:
Originally Posted by DiscoDavis View Post
Looks nice but get it done ASAP. Too many long term thread of torn down cars where they haven't been touched
Yep. Then stuff gets lost/broken/scratched. Do as time allows, but stay on it

Noico is pretty good (Amazon) and less than DynaMat.

At this point, replace windscreen to roof and to bulkhead foam strips. Really cheap and will eliminate possible leaks.
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  #14  
Old January 27th, 2018, 10:14 AM
Stealthsr71
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Jeff Innes
1991 Defender 110
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Big Delivery this week....

New son Dutch Alyster was born on Monday night. We get to bring him home on Sunday.

Also new doors from SP-4x4 came with tons of parts. New Raptor Dash.

Trying to continue rebuild of dash at night and waiting to get back out for more tear down when I can.
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  #15  
Old January 27th, 2018, 11:12 AM
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Jason Lavender
88-90-127-LR3
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Jeff - great project, and congrats on the little one - future garage helper and Defender owner right there. Brainwash him well, I’ve been grooming my kids since birth.

Got an SDO “care package” of parts headed your way .

Also, in the misery-loves-company genre I’m tearing down my IIA as we speak:
http://www.defendersource.com/forum/...ld-129505.html
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  #16  
Old January 27th, 2018, 11:25 AM
Stealthsr71
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Jeff Innes
1991 Defender 110
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Thanks Jason,

Just picked up a few things from you today!

We spoke last year about my clutch and if you remember I had just adopted my 1st son last January. Well his birth mom got pregnant again, and now we have his brother. They can fight one day over the Defender. lol.
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  #17  
Old January 31st, 2018, 02:19 PM
Stealthsr71
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Jeff Innes
1991 Defender 110
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Join Date: Dec 2016
Location: Ponce Inlet, Florida
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Restored/painted black plastic trim for dash to match new door cards.

Cleaned up rust and Por 15 all metal parts in dash that aren't seen. Now onto wrap in new viny.
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  #18  
Old February 11th, 2018, 04:54 PM
Stealthsr71
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Jeff Innes
1991 Defender 110
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So the bad news (for my wife) is the city came by and told me to move my truck in the garage since it’s in repair. Good news is I have a newborn who wakes me up at 4am and I’ve been able to get some progress. Pulled the corner panels to make repairs and replace. Pulled the roof.

Talking to Safari HP about doing a galv chassis swap and to galv dip my bulkhead. I’d take this on but with 1yr old and infant along with house remodel I just don’t think I’d get to it as quickly.
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  #19  
Old February 12th, 2018, 04:00 PM
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GynormousMellon
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Dave
1989 Defender 110
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Quote:
Originally Posted by Stealthsr71 View Post
Thanks Eric, I spoke with you about the new doors from SP4x4. They should be inbound in the next few days.

Goal at the moment, is to start with an on the chassis build. I am going to have the rest of the truck blasted, and painted properly, rebuild dash, all new wiring, interior etc.

The chassis and bulkhead are solid and there is little to no rust. What is there is just surface and can be brushed off and coated with por15.

I hope in some years down the road when my boys are a few years old that we can do a Chassis change over and upgrade the motor.

Since the truck is wide open, I was wondering if anything else should get replaced? Brake lines, Fuel Tank, Fuel Pump, etc.
I'd love to hear how you like the doors.

Sent from my Pixel XL using Tapatalk
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